Roof/wall panel

Abstract: There is disclosed an improved roof/wall panel. Known panels suffer from a number of problems, eg, it has been found that they may become loose in high winds. Accordingly, the invention provides a roof or wall panel (10, 10', 10'', 10a, 10'a, 10b, 10'b, 10''b) comprising a substantially rectangular planer member having an outer layer (40, 40', 40'', 40a, 40'a) characterised in that at least part of the outer layer extends beyond a side edge (51, 51a) of the panel which side edge may form a longitudinal edge, in use, so as to form a raised lip such that when the side edge of the panel is positioned adjacent to an opposing longitudinal side edge (50', 50'a) of another panel the lip of the side edge of the panel overlaps at least part of the opposing side edge of the other panel. In a preferred embodiment the outer layer (40, 40', 40'', 40a, 40'a) is a prelaminated plastics-to-metal layer.

Description: This invention relates to roof or wall panels, and in particular to panels employing a prelaminated plastics-to- metal layer. It is known to use prelaminated plastics-to-metal sheeting in various roofing applications such as in providing backing angles or counter flashing. Also, metal sheet panels are often used in preference to conventional lead or copper roofs, these panels frequently being fabricated from aluminium based alloys. Such panels are secured side by side in a waterproof joint, and are normally clinked together. In the case of metal sheeting, hidden cleat fixings are used to clip the sheets in place. A problem arises, however, in that a high degree of skill requires to be exercised by a tradesman in making the seams between these panels or sheets waterproof. It is an object of this invention to obviate or mitigate the aforesaid disadvantages It is also known from EP-A-0409513, to provide a panel comprising a substantially rectangular planar member having a middle layer of an insulating material and inner and outer layers, and having first and second longitudinal sides the panel being adapted for fitting together with similar panels upon a longitudinal supporting structure which provides upstanding portions extending along and between first and second longitudinal side faces of adjacent panels, the panel having means along the first longitudinal side whereby the panel may be fixed to the upstanding portion of the supporting structure. A problem exists with such previously known panels in that it has on occasion been found that they become loose and/or are removed from a roof by high winds or the like. It is, therefore, an object of the present invention to obviate or mitigate the aforementioned disadvantage. Accordingly, one aspect the present invention provides a roof or wall panel of the type disclosed in EP-A-0409513 characterised in that at least part of the outer layer extends beyond the second longitudinal side of the panel so as to form a raised lip, such that when the second longitudinal side of the panel is positioned adjacent to the first longitudinal side of another panel, said lip will extend over the upstanding portion of the supporting structure and overlap the first longitudinal side edge of the other panel, such that the panel can effectively be fixed to said supporting structure by fixing the lip to said other panel. The opposing longitudinal side edge of the other panel may also be formed with a (raised) lip. In one embodiment of the panel the outer layer may comprise a prelaminated plastics-to-metal layer. The panel may be formed with the inner layer of the panel comprising a metal layer. Further, the panel when it has a prelaminated plastic-to-metal outer layer and/or a metal inner layer may have means along the first longitudinal side which comprises the material of the inner layer extended over the respective longitudinal side. The first longitudinal side of the panel may be fixable to the upstanding portion of the supporting structure by screw fixing means. Each layer may be adhered to an adjacent layer. Alternatively, each layer may not be adhered to an adjacent layer, but be suitably held in relation thereto. The longitudinal edges of the panel may be suitably contoured so that when the side edge of the panel is positioned adjacent to an opposing side edge of another panel a standing seam is formed. The panel may be used in combination with at least one similar panel and at least one T-bar suitable for use in supporting the longitudinal edges of the panels while providing the upstanding portion therebetween. According to a second aspect of the present invention there is provided a roof or wall formed from a plurality of panels fixed to a supporting structure which provides an upstanding portion extending along and between first and second longitudinal side faces of adjacent panels, each panel comprising a substantially rectangular planar member having a middle layer of an insulating material and inner and outer layers, and having first and second longitudinal sides said first longitudinal side having means whereby the panel may be fixed to the supporting structure, the first longitudinal side of a first panel being fixed to the upstanding portion of the supporting structure, characterised in that at least part of the outer layer of a second panel extends beyond the second longitudinal side of the second panel so as to form a raise lip and extends over the upstanding portion of the supporting structure and overlaps the first longitudinal side of the adjacent first panel, and is fixed thereto such that the second longitudinal side of the second panel is effectively fixed to the supporting structure by fixing of the lip to the first panel. A roof or wall so formed may include means along the first longitudinal side of the first panel which comprises the inner layer extended over the respective longitudinal side. In one embodiment the roof or wall may include a supporting structure comprising a plurality of fixed substantially parallel inverted T-bars spaced so as to receive at least one panel between adjacent pairs of T-bars the thickness of each panel being greater than the height of the inverted T-bars. A panel may be fixed in position by means of suitable fixing means, such as a self tapping screw(s) which pass through and retain in abutting contact an elongated portion of an inverted T-bar and the means for fixing on the first longitudinal side edge of the first panel. According to a third aspect of the present invention there is provided a method of fixing panels to a supporting structure, to form a wall or roof from a plurality of panels, each panel comprising a middle layer of an insulating material and inner and outer layers, and having first and second longitudinal sides the panel being adapted for fitting together with similar panels upon a supporting structure which provides upstanding portions extending along and between first and second longitudinal side faces of adjacent panels, the panel having means along the first longitudinal side whereby the panel may be fixed to the upstanding portion of the supporting structure, which method comprises: locating and securing support members having an upstanding portion so as to form the supporting structure; slidably locating between two adjacent support members a first panel; fixing said first panel via the means in the longitudinal side to the upstanding portion of one of said support members using suitable fixing means passing through the upstanding portion of the support member to retain the panel in place; slidably locating a second panel adjacent said first panel between two support members so that the two panels so located with at least one support member in common and with their respective first and second longitudinal edges adjacent; and fixing said second panel to a support member as with said first panel; characterised in that the second panel further includes at least part of the outer layer extending beyond the second longitudinal side of the panel so as to form a raised lip, whereby when the second longitudinal side of one of the panels is positioned adjacent to the first longitudinal side of the other panel, said lip extends over the upstanding portion of the supporting structure and overlaps the first longitudinal side edge of the other panel, and wherein the method further includes: securing said outer layer extending over the adjacent panel to said adjacent panel and thereby effectively fixing the second longitudinal edge of the second panel to the supporting structure. The method may include filling the space between the adjacent panels with a thermal block. The thermal block may be polyisobutalane which is injected between the panels. The method may also include locating a weather-proofing strip over the longitudinal sides of the adjacent panels, and securing the weather-proofing strip in place. An embodiment of the present invention will now be described, by way of example only, with reference to the accompanying drawings, which are: Fig 1 a partial perspective view of a roof employing panels according to a first embodiment of the present invention; Fig 2 a partial transverse cross-sectional view of two longitudinal adjacent panels on the roof of Fig 1; Fig 3 a partial longitudinal cross-sectional view of two transversely adjacent panels on the roof of Fig 1; and Fig 4 a partial perspective cross-sectional view of two tranversely adjacent panels illustrated as alternative transverse edge join arrangements. Referring now to Figs 1 and 2, there are shown two substantially rectangular planar roofing panels 10,10' according to a first embodiment of the present invention. Each of these panels 10,10' comprises a substrate metal layer 20,20' fabricated from a suitable metal (approximately 1mm to 3mm thick), an extruded polystyrene foam middle insulating layer 30,30' (approximately 5cm to 10cm thick), and a topmost (outermost) prelaminated plastics-to-metal layer 40,40' (approximately 1mm to 5mm thick), the plastic laminate being on the outermost surface of the panels 10,10'. In this embodiment the substrate metal layer 20,20' and the insulating layer 30,30', and also the insulating layer 30,30' and the topmost prelaminated layer 40,40', are adhered to one another using suitable conventional adhesives. Further, in a preferred size each panel 10,10' is approximately 0.6m wide and 2m long. In addition, the longitudinal edges 50', 51' include a pop rivet 275 which fixes the top most prelaminate layer 40, 40' to the substrate metal layer 20, 20' with a strip of mastic between the two layers. This pop rivet 275 is normally factory fitted. As can be seen from Figs 1 and 2, each panel 10,10' has two longitudinal edges 50,51,50',51'. The topmost layer 40,40' extends beyond the longitudinal side edge 51,51' of the panel 10,10' so as to form a raised lip 52,52'. It is, therefore, apparent that, in use, when an edge 51 of a panel 10 is positioned longitudinally adjacent to an opposing edge 50' of another panel 10' the lip 52 of the edge 51 of the panel 10 overlaps the opposing side edge 50' of the other panel 10'. Further, the longitudinal edges 50,50', 51,51' of the panels 10,10' are shaped or contoured in such a way that when two panels 10,10' are placed with the longitudinal edges 50,50' of the panel 10 adjacent the longitudinal edge 50 of the other panel 10' then the two adjacent edges 51, 50' form a standing seam 60, the standing seam 60 running the whole length for which the panels 10,10' are adjacent. A compatible flexible plastic membrane strip 70 is provided, the strip 70 being fixed by hot welding over, and along the length of, the standing seam 60, to provide a water-tight joint. As shown in Fig 3 each panel 10,10" may be fabricated such that one of the transverse edges 80,80", ie, the transverse edge 80 to be placed lowermost on an inclined roof, provides a raised lip 81 (approximately 1cm to 10cm long) such that when panels are placed on a roof the join between the lowermost edge 80 of one panel 10 and the uppermost edge 80" of an adjacent panel 10" will be covered by the lip 81 thus reducing the likelihood of water leaking through transverse joints between adjacent panels 10,10". In addition the lip 81 of panel 10 is joggled up and a corresponding portion of the panel 10" is joggled down so that the join between the panels form a mock welt. Further the upper edge of each panel 10" may be provided with a lip 82" for supporting and accepting a lowermost surface of an adjacent panel 10 and obviate the need for a cross tee or noggin. The adjacent surfaces of respective lips 81,82" and panel layers 40", 20 may be adhered and sealed by, for example, tremco tape 83,83" or the like. Further, a thermal break 90 made, for example, from a suitable expanding filler may be inserted within the standing seam 60, the break 90 further providing means for strengthening structural support at or near the standing seam 60. The insulating layer 30, 30' will be tailored to meet the requirements of the statutory U value, dependent upon whether the panels 10,10' are to be used in a commercial or a domestic application. In use, each panel 10,10' may be slidably located between two pre-fixed rails or inverted T-bars 210 which may be made from metal and at least partially plastic coated. In this embodiment, in which the panels 10,10' are roofing panels, the T-bars 210 are secured to purlins 220 of a roof structure, eg, by screws 221 but the T-bar fixing can be altered depending on the thickness and grade of steel. A cover 225 can be provided over the T-bar 210 through which the screws 221 pass, the cover 225 being provided to cloak and match the finishes. Further, a vapour barrier 230 comprising strips of mastic is located on the T-bar 210. The T-bars 210 may be solid or may be formed of two L-shaped steel angles welded back-to-back from 1.66 mm ingauge or stock steel. The substrate layer 20,20' of each panel 10,10' bends into two longitudinal sides 240, 240' these sides extend above the height of the T-bars 210 and are bent over at their upper ends to form lips 250, 250' which overlie the substrate layer 20,20'. The substrate layer 20,20' and sides 240,240', therefore, form a tray 251, 251'. The top most layer 40,40' of prelaminated plastics-to-metal sheeting is located over the tray 251, 251' and secured to the lips 250,250' by pop rivets 270,270' at intervals along the length of the tray 251,251'. The pop rivets 270, 270' are site fixed and join the panels together. The panel 10' is fixed to the T-bar 210 at side edge 240' adjacent edge 50' by one or more suitable longitudinal spaced fixings such as screws, for example, self tapping screws 271 which pass through longitudinal spaced predrilled holes in an elongated upstanding portion 272 of the inverted T-bar 210 and through the adjacent side edge 240' of the panel 10'. In this way the T-bar 210 and panel 10' are retained in abutting contact. Further, it should be noted that this method allows the T-bars 210 to be standard sized and eliminates the necessity for landing on purlins. At one end of the panel 10,10' (the upper end in use), the plastics laminate which is bonded to the metal sheeting by adhesive may be turned back on itself to form a welt (not shown). In this embodiment, within the formed space between the substrate layer 20,20', the side 240,240' and the topmost layer 40,40' the foam insulation layer 30,30' is provided. The insulation 30,30' may be cut from a block and fitted during assembly of the panel 10,10', or it may be injected into the space through a rivet hole (not shown), eg provided in a side wall 240,240' which hole may be subsequently used when securing the tray 251,251' in place between two T-bars 210,210' via the predrilled holes in the T-bars 210,210'. As illustrated in Fig 2, when two panels 10,10' are in position, there is a space above the T-bar 210,210' and between the upper ends of the tray sides 240,240'. That space is filled by the filler 90, e.g a bituminous based material such as polyisobutylene, to form a cold-bridge insulation. The strip 70 of weatherproofing material is then laid over the open edge of the standing seam 60 and heat welded or otherwise bonded to the lips 52,52' of the adjacent panels 10,10'. The material of the weatherproofing strip 70 is compatible with the plastics membrane of the outer layer 26 of the panels 10,10', and may be the same material, eg. PVC. Once the weatherproofing strip 70 has been laid, a contoured capping cover strip 360 of plastics-to-metal sheeting can be secured over the standing seam 280 by cleats 361 held by screws or rivets 362 which fix the cleat (GALV) through the overlap of the panel, the capping 360 having sides 370 which extends along the sides of the standing seam 60. The capping 360 may alternately be secured by adhesive or other means. The cleats 361 may be approximately 200mm long while the capping 360 may be approximately 2m long. Knuckles 380 may finally be placed over joints between adjacent capping pieces 360. The knuckles 380 have welted sides, and are, therefore, held in place by friction only. In this embodiment disclosed herein, the panels 10,10' are approximately 2m in length so several panels may be mounted between each pair of T-bars 210, the panels 10,10' being placed end to end. Particularly, it is to be understood that the longer or shorter edges of the panels 10,10',10" may constitute the longitudinal edges 240,240' the T-bars 210 being suitably spaced accordingly. Further, the rows of panels 10,10' between adjacent pairs of T-bars 210 are 'staggered' so that the transverse joints are located in different positions. Also, the underside of each panel 10,10' may be finished, eg, with stove paint enamel to form a decorative surface. Further, whilst the panels 10,10',10" have been described as roofing panels, it is to be understood that the panels may be applied as a wall or partition or as a facia. The lip 52 provided on a longitudinal edge of a panel 10 provides particularly advantageous characteristics of the panel 10 of the present invention over those of the prior art. The lip 52 (or "overlap") provides added strength to the roof or wall made from a plurality of such panels 10,10',10". Further, in known roofs, ends of the inverted T-bars have always needed to be placed upon and attached to the purlins. It has surprisingly been found that employing panels according to the present invention the T-bars may be attached to the purlins at any point along the length of the T-bar and that the ends of the T-bars may extend beyond the purlins, in use (see Fig 1). Referring now to Fig 4 there is illustrated panels 10b, 10"b showing an alternative transverse fixing arrangement. Such panels 10b, 10"b are retained in association with one another along their adjacent transverse edges by a reinforced PVC membrane 83b (eg. approximately 0.9mm thick). The method of fixing the panels 10b, 10"b with respect to each other, which method includes: welding the membrane 83b of unreinforced PVC to the underside of the lip 81 of the panel 10b; welding the membrane 83b to the lower panel 10"b and to the upstand of the bottom panel to hold down a second piece which is formed flat or tapered; checking out the top skin of the panel 10b to accommodate the PVC strip; welding a PVC soaker 84b over the ends of the PVC membrane 83b of adjacent panels; and locating and fixing capping 85b over the standing seam. Finally the embodiment of the invention disclosed herein provides a particularly simple and easily constructed solution to long-standing problems experienced within this art. It will, however, be appreciated that modifications may be made within the scope of the invention as defined in the amended claims.

Claims: A roof or wall panel (10) comprising a substantially rectangular planar member having a middle layer (30) of an insulating material and inner (20) and outer (40) layers, and having first and second longitudinal sides (50, 51) the panel being adapted for fitting together with similar panels (10') upon a longitudinal supporting structure which provides upstanding portions (272) extending along and between first and second longitudinal side faces of adjacent panels, the panel having means (240') along the first longitudinal side whereby the panel may be fixed (271) to the upstanding portion of the supporting structure characterised in that at least part of the outer layer extends beyond the second longitudinal side of the panel so as to form a raised lip (52), such that when the second longitudinal side of the panel is positioned adjacent to the first longitudinal side (50') of another panel, said lip will extend over the upstanding portion of the supporting structure and overlap the first longitudinal side edge of the other panel, such that the panel can effectively be fixed to said supporting structure by fixing the lip to said other panel. A panel as claimed in claim 1, wherein the outer layer of the panel comprises a prelaminated plastics-to-metal layer (40, 40'). A panel as claimed in claim 1 or 2, wherein the inner layer of the panel comprises a metal layer (20, 20'). A roof or wall panel as claimed in claim 2 or 3, wherein the means (240) along the first longitudinal side comprises the material of the inner layer (20) extended over the respective longitudinal side. A roof or wall panel as claimed in any preceding claim, wherein the first longitudinal side of the panel is fixable to the upstanding portion of the supporting structure by screw fixing means (271). A panel as claimed in any preceding claim, wherein each layer is adhered to the adjacent layer. A roof or wall panel as claimed in any preceding claim, wherein the first and second longitudinal edges of the panel are suitably contoured so that when the side edge of a panel is positioned adjacent to an opposing side edge of another panel a standing seam (60) is formed. A roof or wall panel as claimed in any preceding claim, in combination with at least one similar panel (10') and at least one T-bar (210) suitable for use in supporting the longitudinal edges of the panels while providing the upstanding portion (272) therebetween. A roof or wall formed from a plurality of panels (10, 10') fixed to a supporting structure (210, 220) which provides an upstanding portion (272) extending along and between first and second longitudinal side faces of adjacent panels, each panel comprising a substantially rectangular planar member having a middle layer (30) of an insulating material and inner (20) and outer (40) layers, and having first and second longitudinal sides (50, 51), said first longitudinal side (50) having means (240') whereby the panel may be fixed to the supporting structure, the first longitudinal side (240') of a first panel being fixed (271) to the upstanding portion of the supporting structure, characterised in that at least part of the outer layer of a second panel extends beyond the second longitudinal side of the second panel so as to form a raised lip (52)and extends over the upstanding portion (272) of the supporting structure and overlaps the first longitudinal side of the adjacent first panel, and is fixed thereto (270') such that the second longitudinal side (51) of the second panel (10) is effectively fixed to the supporting structure by fixing of the lip to the first panel. A roof or wall as claimed in claim 9, wherein the means (240) along the first longitudinal side of the first panel comprises the inner layer extended over the respective longitudinal side. A roof or wall as claimed in claim 9 or 10, wherein the supporting structure comprises a plurality of fixed and substantially parallel inverted T-bars (210) spaced so as to receive at least one panel (10, 10') between adjacent pairs of T-bars, the thickness of each panel being greater than the height of the inverted T-bars. A roof or wall as claimed in claim 11, wherein the panels are fixed in position by fixing means (271), which pass through and retain in abutting contact the upstanding portion of an inverted T-bar and the means (240) for fixing on the first longitudinal side of the first panel. A roof or wall as claimed in claim 9, 10, or 11, wherein the first and second panels comprise panels as claimed in one or more of claims 1 to 8. A method of fixing panels (10, 10') to a supporting structure (210, to form a wall or roof from a plurality of panels, each panel comprising a middle layer (30) of an insulating material and inner (20) and outer (40) layers, and having first and second longitudinal sides (50, 51) the panel being adapted for fitting together panels (10') upon a supporting structure which provides upstanding portions (272) extending along and between first and second longitudinal side faces of adjacent panels, the panel having means (240') along the first longitudinal side (50') whereby the panel may be fixed to the upstanding portion of the supporting structure, which method comprises: locating and securing support members (210) having an upstanding portion (272) so as to form the supporting structure; slidably locating between two adjacent support members a first panel (10'); fixing said first panel via the means (240') in the longitudinal side to the upstanding portion (272) of one of said support members using suitable fixing means (271) passing through the upstanding portion of the support member to retain the panel in place; slidably locating a second panel adjacent said first panel between two support members so that the two panels so located with at least one support member in common and with their respective first and second longitudinal edges adjacent; and fixing said second panel to a support member as with said first panel; characterised in that the second panel further includes at least part of the outer layer extending beyond the second longitudinal side of the panel so as to form a raised lip (52), whereby when the second longitudinal side of one of the panels is positioned adjacent to the first longitudinal side (50') of the other panel, said lip extends over the upstanding portion of the supporting structure and overlaps the first longitudinal side edge of the other panel, and wherein the method further includes: securing (270') said outer layer extending over the adjacent panel to said adjacent panel and thereby effectively fixing the second longitudinal edge of the second panel to the supporting structure. A method as claimed in claim 14, wherein a space between the adjacent panels is part filed with a thermal block (90). A method as claimed in claim 15, wherein the thermal block is polyisobutylene and is injected between the panels. A method as claimed in any of claims 14 to 16, in which the method further comprises locating a weather-proofing strip (70) over the longitudinal sides of the adjacent panels, and securing the weather-proofing strip (70) in place.

Inventors: MCNEIL ROBERT TELFER, MCNEIL, ROBERT TELFER
Applicants: MCNEIL ROBERT TELFER, MCNEIL, ROBERT TELFER
Application year: 1994
Main classification: E04C2
IPC codes: E04D3, E04D13, E04C2